Trailer coupler

ABSTRACT

A trailer coupler may be provided with an opening and socket for a hitch ball, and a clamping bar in an internal channel for locking the coupler and hitch together. The internal channel may extend horizontally and be positioned above the opening and below the socket. The channel may include a laterally-facing aperture adjacent the second end, out of which one end of the clamping bar may extend. That end of the clamping bar may include a bracket with an open channel to fit over a flange on the coupler body. The coupler may be assembled by inserting a first end of the clamping bar through the laterally-facing aperture, and moving the first end of the clamping bar into the coupler body channel while fitting the bracket over the flange at the open channel of the clamping bar.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is continuation-in-part of U.S. patentapplication Ser. No. 14/300,002, filed Jun. 9, 2014, which is acontinuation of U.S. patent application Ser. No. 13/485,785, filed May31, 2012, which claims priority to U.S. Provisional Patent ApplicationSer. No. 61/491,840, filed May 31, 2011, all of which are incorporatedby reference herein.

BACKGROUND

The present invention relates to a structure and components for atrailer coupler that attaches to the hitch ball of a towing vehicle. Thestructure and components are particularly suited to the gooseneckvariety of trailer couplers but may also be used in other varieties ofcouplers. Gooseneck couplers typically extend downwardly from a nose ofthe trailer and provide a socket to receive a hitch ball. Such couplerstypically include at a lowermost position a locking plate having a holethat can be aligned with the socket to receive the hitch ball, andmisaligned so as to retain the hitch ball in the socket

BRIEF SUMMARY

According to one embodiment of the present invention, a trailer couplerfor installation at a forward end of a trailer may be configured toattach to a hitch of a towing vehicle. The coupler may include anopening for the hitch ball, a socket to receive the ball, and aninternal channel for a clamping bar. The internal channel may extendhorizontally and be positioned above the opening and below the socket.The channel may include a laterally-facing aperture adjacent the secondend, out of which one end of the clamping bar may extend. That end ofthe clamping bar may include a bracket with an open channel to fit overa flange on the coupler body.

According to an embodiment of the present invention, a method ofassembling a trailer coupler may include inserting a first end of theclamping bar through the laterally-facing aperture, and moving the firstend of the clamping bar into the coupler body channel while fitting thebracket over the flange at the open channel of the clamping bar.

According to another embodiment of the present invention a handle formoving the clamping bar may be provided with detents for an openposition and a locked position for the clamping bar.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a trailer coupler according to anembodiment of the present disclosure, showing portions of the trailerand towing vehicle and the hitch as well as the main shaft and couplerbody with a handle to position and control the locking of the coupler.

FIG. 2 is a perspective view of the trailer coupler of FIG. 1, partiallyfrom below, showing the opening for the ball and the clamping bar abovethe opening.

FIG. 3 is a view from directly below the trailer coupler showing aflange with a locking hole, and, in phantom lines, the clamping bar, anda channel and a spring for the clamping bar.

FIGS. 4a and 4b are cross-sectional views of the coupler body, bothwithout and with the clamping bar installed, respectively.

FIG. 5 is a plan view of the clamping bar.

FIG. 6 is a perspective view of an embodiment of the trailer coupler ofFIG. 1 showing another arrangement for the clamping bar above theopening for the ball.

FIG. 7 is a perspective view of the trailer coupler of FIG. 6 showing ahandle for moving the clamping bar between an open position (shown) anda locked position (see FIGS. 8 and 12).

FIG. 8 is a perspective view of the trailer coupler of FIG. 6 showing ahandle for moving the clamping bar between an open or unlocked position(see FIGS. 7 and 11) and a locked position (shown).

FIG. 9 is a perspective, close-up view of the clamping bar above theopening of the trailer coupler of FIG. 6, shown in the open position.

FIG. 10 is a perspective, close-up view of the clamping bar above theopening of the trailer coupler of FIG. 6, shown in the locked position.

FIG. 11 is a perspective view of the trailer coupler of FIG. 6 showingthe handle for moving the clamping bar between the open position (shown)and the locked position (see FIGS. 8 and 12).

FIG. 12 is a perspective view of the trailer coupler of FIG. 6 showing ahandle for moving the clamping bar between an open or unlocked position(see FIGS. 7 and 11) and a locked position (shown).

FIG. 13 is a cross-section of the trailer coupler of FIG. 6 showing theclamping bar moved to the locked position by the handle.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2, a trailer coupler 10 in accordance with thepresent description has an external appearance much the same asconventional trailer couplers of the gooseneck variety. Trailer coupler10 may include an upwardly extending pipe, tube, or shaft 12 forattachment to a trailer TR at a brace or bracket 14 at the front orforward end of trailer TR. Shaft 12 may be in one or two sections 16, 18or otherwise configured for adjustability in height, for example, ascontrolled by the relative positioning of sections 16, 18 as fixed by apin 20.

Trailer coupler 10 may be coupled to a towing vehicle TV at a hitch 22that typically includes a ball 24 and a neck 26 below the ball. Whencoupled, ball 24 is inside coupler 10 and a socket 28 rests on ball 24,allowing for articulation of the trailer relative to the towing vehiclewith the general degrees of freedom associated with a ball-and-socketarrangement.

A handle 30 with a locking pin 32 is operable to lock the coupler ontothe ball to prevent disconnection of the hitch and coupler, while stillallowing relative rotational movements at the ball-and-socket interface.The operation and structure appears generally the same as forconventional gooseneck trailer couplers, however an external differenceis that a coupler body 34, which conventionally is a two-piececombination of a socket body with a locking plate, may be formed in asingle piece, preferably by casting.

In the coupler body of the present embodiment, a downwardly-facingopening 36 is configured to allow ball 24 to pass therethrough and intosocket 28 above opening 36. Socket 28 receives ball 24 in a matingarrangement allowing rotational movement as described above.

As will be described in more detail for FIGS. 3-6, a clamping bar 38 incoupler body 34 may be positioned between opening 36 and socket 28, thatis, above opening 36 and below socket 28. Clamping bar 38 may beoperated to a locked position (shown in FIG. 2) which will hold ball 24in socket 28 and prevent the ball from passing back out through theopening. Clamping bar 38 is held in the locked position by lock pin 32as will be further described. Typically, in the locked position, acurved middle portion 40 of clamping bar 38 is positioned to partiallyblock opening 36 and may contact neck 26 of ball 24. This positioning ofclamping bar 38 tends to hold the ball in the socket.

As seen in FIGS. 2-3, opening 36 may be defined by a circular edge 42that typically is an upper end of a frustoconical section 44 that has alower end 46. Section 44 may be useful in guiding ball 24 into andthrough opening 36 when initially misaligned.

As best seen in FIG. 4a , with clamping bar 38 removed, coupler body 34includes an internal channel 48 extending horizontally between a firstend 50 and a second end 52. Internal channel 48 is preferably positionedabove opening 36 and its circular edge 42, and below socket 28.

Internal channel 48 typically includes a laterally-facing aperture 54adjacent second end 52, and may also include another laterally facingaperture 56 adjacent its first end 50. One or both of thelaterally-facing apertures may be used during assembly for insertion andinstallation of clamping bar 38.

A side wall 58, preferably a portion of the single-piece, uni-bodycasting of coupler body 34, may enclose a side of channel 48. A biasingmember, such as a spring 60 may be installed in side wall 58, orelsewhere, as suited to biasing clamping bar 38 into the lockedposition. Spring 60 may be installed in a through-hole 62 in wall 58,and then held in place by a welded closure 64 or a nut threaded intoplace, or installed by any other suitable means.

As seen in FIG. 4b , clamping bar 38 may define a first end 66 withinfirst end 50 of channel 48. Clamping bar 38 typically includes curvedmiddle portion 40 adjacent opening 36. Clamping bar 38 may have a secondend 68 extending out of laterally-facing aperture 54 of channel 48.

Clamping bar 38 is preferably movable between an open position and thelocked position (FIGS. 2 and 3). In the open position, the clamping baris typically substantially clear of opening 36 to allow ball 24 to passtherethrough. For movement between the positions, clamping bar 38 may bemounted on a pivot joint, such as one formed by a rod or bolt 70 incoupler body 34 adjacent first end 50 of channel 48. Rod or bolt 70 maybe held in place in coupler body 34 by any suitable means such aswelding or fastening with a nut, and clamping bar 38 may be mountedthereon at a through-hole 72. Such a pivot joint allows pivotal movementof the clamping bar between the locked position and the open position.

Second end 68 of clamping bar 38 typically includes a bracket 74 thatfits over a flange or protrusion 76 on coupler body 34. Bracket 74 mayinclude a lower portion 78, side portions 80 and upper portion 82.Preferably, holes 84, 86, and 88 are provided through upper portion 80,flange 76, and lower portion 78, respectively. The holes are positionedto be aligned when clamping bar 38 is in the locked position. Lockingpin 32 on handle 30, in the locked position preferably extends throughholes 84, 86, and 88.

Handle 30 is typically spring-loaded downwardly to hold the pin in thelocked position. Handle 30 may be associated with a sheath 90 mounted onshaft 12 that supports the handle and provides a detent 92 to whichhandle 30 may be shifted to hold the locking pin 32 away from holes 84,86, and 88.

As noted above, coupler 34 is preferably formed in a single casting tohave a unitary body with features such as socket 28, opening 36,frustoconical section 44, channel 48, and/or lateral openings 54, 56already formed therein. Coupler body 34 may be machined and/or otherwiseprocessed to form one or more of its features.

Installation of clamping bar 38 may be facilitated by lateral openings54, 56, and by the particular shape of bracket 74 and flange 76. Forexample, clamping bar 38 may be inserted into channel 48 starting withfirst end 66 of bar 38 at channel aperture 54. By this method, clampingbar 38 may be moved within channel 48 until first end 66 is adjacentchannel first end 50. Alignment of hole 72 for insertion of rod or bolt70 may be facilitated by access to bar 38 via channel aperture 56.

The curvature of bar 38, as well the shape and size of an open channel94 through bracket 74 may be coordinated with a shape of flange 76 tofacilitate insertion of bar 38 into channel 48. For example, bar 38 maybe substantially straight between first end 66 and curved middle portion40 and then curve in an opposite direction at a curved portion 96between the middle and the second end 68. Bracket 74 may be alignedsubstantially perpendicularly to second end 68. Open channel 94 ofbracket may be provided with side walls 98, 100, one or both of whichmay be narrowed on an inner side 102 to facilitate installation ofbracket 74 over flange 76. A curvature 104 may be provided on flange 76similarly to facilitate insertion of bracket 74 over flange 76. Channel48 may be further defined by a floor 106 and ceiling 108.

Spring 60 may be externally inserted through side wall 58 afterinstallation of bar 38. Alternatively, it may be installed in hole 62prior to installation of the bar 38.

As shown in FIGS. 6-12, a trailer coupler 110 includes a clamping bar138 operable between an open position and a locked position. Coupler 110typically has an external appearance much the same as conventionaltrailer couplers of the gooseneck variety. Trailer coupler 110 mayinclude an upwardly extending pipe, tube, or shaft 12 for attachment toa trailer in the same manner as described for FIGS. 1-5. Shaft 12 may bein one or two sections and/or otherwise configured for adjustability inheight, for example, as controlled by the relative positioning of thesections as described for FIGS. 1-5.

Trailer coupler 110 may be coupled to a towing vehicle at a hitch thattypically includes a ball, and a neck below the ball, as described forFIGS. 1-5. When coupled, the ball is inside coupler 110 and a socket 128rests on the ball 24, allowing for articulation of the trailer relativeto the towing vehicle with the general degrees of freedom associatedwith a ball-and-socket arrangement as described for FIGS. 1-5.

As shown in in FIGS. 7-8, a handle 130 with a locking pin 132 (FIGS.11-12) is operable to lock the coupler onto the ball to preventdisconnection of the hitch and coupler, while still allowing relativerotational movements at the ball-and-socket interface. Handle 130 may bemounted on a hinge pin 200, e.g., a bolt, inserted in through holes in acoupler body 134, and held in place by a nut or any other suitablearrangement for a hinged or other operable mount for handle 130. Theoperation and structure appears generally the same as for conventionalgooseneck trailer couplers, however an external difference is thatcoupler body 134, which conventionally is a two-piece combination of asocket body with a locking plate, may be formed in a single piece,preferably by casting.

In coupler body 134, a downwardly-facing opening 36 is configured toallow the hitch ball 24 to pass therethrough and into socket 128 aboveopening 36. Socket 128 receives ball 24 in a mating arrangement allowingrotational movement as described above.

Clamping bar 138 is positioned similarly within coupler body 134 andgenerally operates in a manner similar as described for FIGS. 1-5, withrefinements described herein. Socket 128 may be generally semi-sphericaland may include a hollowed-out portion 210 that defines a lip 212opposite clamping bar 138. The hollowed-out portion 210 is typicallycurved to receive the hitch ball and clamping bar 138 may include asimilarly curved, hollowed-out portion 214 defining a lip 216. The lipsand hollowed-out portions of the socket 128 and clamping bar 138 maycombine to hold the hitch ball in the socket in the locked configurationsimilar to the operation of the socket and clamping bar for FIGS. 1-5.

Clamping bar 138 may be operated to a locked position (shown in FIGS. 8,10, and 13) which will hold the hitch ball in socket 128 and prevent theball from passing back out through the opening. Clamping bar 138 is heldin the locked position by a shoe 218 coupled to handle 130 as will befurther described. Typically, in the locked position, a lip 216 ofclamping bar 138 is positioned to partially block opening 36 and maycontact the neck portion of the hitch ball. This positioning of clampingbar 138, whether or not aided by opposed lip 212, tends to hold the ballin the socket.

As seen, e.g., in FIG. 6, and similar to FIGS. 1-5, opening 36 may bedefined by a circular edge 42 that typically is an upper end of afrustoconical section 44 that has a lower end 46. Section 44 may beuseful in guiding the hitch ball into and through opening 36 wheninitially misaligned. Coupler body 134 includes an internal channel 148(FIG. 13) where clamping bar 138 may be mounted, e.g, pivotally mountedon pin 170. The mount for clamping bar 138 may include a means forbiasing clamping bar 138 to a position, such as the open position, e.g.,by a spring mounted on pin 170. Internal channel 148 typicallycommunicates with one or both of the sets of holes for the pin 170 forthe clamping bar and the pin 200 for the handle, as well as a pair ofholes 186, one of which is shown in FIGS. 10 and 13, for receiving alocking pin 132 (FIGS. 11 and 12).

Clamping bar 138 is preferably movable between an open position (FIGS. 7and 9) and the locked position (FIGS. 8, 10, and 13). In the openposition, clamping bar 138 is typically substantially clear of opening36 to allow the hitch ball to pass therethrough. As noted above, formovement between the positions, clamping bar 138 may be mounted on apivot joint, such as one formed by a rod or bolt 170 in coupler body 134in channel 148. Rod or bolt 170 may be held in place in coupler body 134by any suitable means such as by cotter pin(s), or welding or fasteningwith a nut, and clamping bar 138 may be mounted thereon. Such a pivotjoint allows pivotal movement of the clamping bar between the lockedposition and the open position.

In the locked position of clamping bar 138, lip 216 may be in contactwith the neck portion of the hitch ball. A surface 220 (FIG. 13) ofclamping bar 138 may be provided on the clamping bar adjacent to, and ona side opposite from, lip 216. Surface 220 typically faces shoe 218, andthe clamping bar may be moved into the locked position by the shoe'spressing on surface 220. As will be described below, the coupler isretained in the locked configuration by insertion of a locking pin 132that prevents shoe 218 and clamping bar 138 from moving out of thelocked position.

Handle 130 may be provided with any suitable shape, e.g., the curved,hourglass shape shown in FIGS. 7-8 and 11-12 designed ergonomically forgrasping and operation by the human hand. As shown in FIG. 13, handle130 typically includes a sliding portion 232 that is movable along a rod234 that resides within an internal channel 236 of sliding portion 232.The sliding portion may be spring-loaded downwardly, i.e., in thedirection towards hinge pin 200, e.g., by a spring 238 within channel236, to hold the handle in each of the open position and the lockedposition. Rod 234 may be pivotally mounted on hinge pin 200.

To move handle 130 from the open position of FIGS. 7 and 11 to thelocked position of FIGS. 8 and 12, the user grasps the sliding portionof the handle and pulls it radially away from pin 200 while also movingthe entire handle rotationally about the pivot defined by pin 200.Pulling the sliding portion radially away from pin 220 allows the handleto pass over a pair of bosses 222 that define detents 224, 226 for thehandle in each of the locked position (226) and the open position (224).

A corresponding operation may be used to move the handle, and the shoeand clamping bar, from the locked position to the open position. Bosses220 typically are present to prevent inadvertent movement of handle 130(and thus shoe 218 and clamping bar 138) between the open and lockedpositions, absent the user's operation as just described. In the lockedposition, locking pin 132 may be inserted through holes 186 provided incoupler body 134 to hold the handle, shoe, and clamping bar in thelocked position. Locking pin 132 may be held in place in holes 186 by aclip 228 or other suitable means. Locking pin 132 may be connected tothe coupler body by a chain 230 for retaining the locking pin or anyother suitable attachment for retaining the locking pin when not ininstalled in holes 186.

Typically shoe 218 is directly mechanically coupled to handle 130 topivot about pin 200 proportionally to the movement of handle 130, e.g.,by shoe 218 being an opposite end of rod 234. Other configurations ofthe shoe and handle may be used for suitable movement of the clampingbar for a particular application.

Coupler 134 is preferably formed in a single casting to have a unitarybody with features such as socket 128, opening 36, frustoconical section44, and/or channel 148, already formed therein. Coupler body 134 may bemachined and/or otherwise processed to form one or more of its features,such as the holes for mounting pin 170, pin 200, and locking pin 132.

A typical combination of a trailer with a towing vehicle is for thecoupler to be part of the trailer and in the orientation as describedherein, and the hitch to be part of the towing vehicle and in theorientation as described herein. Alternatively, the coupler may be partof the towing vehicle and the hitch part of the trailer and theorientation of the parts may be switched or otherwise altered. Termssuch as downwardly facing opening are to be understood as explaining thepreferred embodiment and as incorporating different possibleorientations within the scope of the present description.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in any claims are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theembodiment was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious embodiments with various modifications as are suited to theparticular use contemplated.

What is claimed is:
 1. A trailer coupler for installation at a forwardend of a trailer, the coupler configured to attach to a hitch of atowing vehicle, the hitch defining a ball and a neck below the ball, thecoupler comprising: a. a coupler body including i. a downwardly-facingopening configured to allow the ball to pass therethrough, ii. a socketabove the opening for receiving the ball, and iii. an internal channel,b. a clamping bar including a first portion adjacent the opening andincluding a second portion pivotally mounted within the internal channelof the coupler body, the clamping bar pivotable between a lockedposition and an open position, the opening-adjacent first portion of theclamping bar in the locked position being positioned to partially blockthe opening and configured to contact the neck of the ball to hold theball in the socket, and further including a pin selectively operable tohold the clamping bar in the locked position; c. a handle mounted to thecoupler, the handle movable between a first, locked position and asecond, open position, wherein the first, locked position of the handlecorresponds to the locked position of the clamping bar, and wherein thecoupler provides a detent for the second, open position; and d. a firsthole and a second hole in the coupler, wherein each of the first andsecond holes is configured to receive therethrough the pin that isselectively operable to hold the clamping bar in the locked position,further wherein the pin is inserted through each of the first hole andthe second hole to hold the clamping bar in the locked position.
 2. Thecoupler of claim 1, further including a means for biasing the clampingbar to one of the locked and the open positions.
 3. The coupler of claim2 wherein the biasing means biases the clamping bar to the lockedposition.
 4. The coupler of claim 2 wherein the biasing means biases theclamping bar to the open position.
 5. The coupler of claim 1 furtherwherein coupler body is formed substantially as a one-piece casting. 6.The coupler of claim 4 wherein the coupler body further includes a holefor mounting a hinge pin for pivotal mounting of the clamping bar. 7.The coupler of claim 1 wherein the first and second holes are in theclamping bar, and further including a third hole through the couplerbody.
 8. The coupler of claim 1 wherein the first and second holes arein the coupler body.